Pallet Rack Systems

Selective pallet rack accounts for roughly 85% of all pallet rack installations. It provides direct forklift access to every pallet position and works for nearly any warehouse operation.

Three primary strategies: (1) Narrow aisle or VNA rack to reduce aisle widthsand gain 40–50% more positions, (2) Mobile pallet rack to eliminate aisles entirely for up to 80% more positions, or (3) high-density systems like drive-in or push-back for bulk storage.

Structural pallet rack handles temperature extremesand forklift impact best. Many cold storage operations also use mobile rack on structural frames to maximize expensive refrigerated space.

Standard selective rack uses roll-formed (bent sheet metal) components. Structural rack uses hot-rolled steel C-channelsand I-beams — heavier, more impact-resistant, and better suited for abusive environments like cold storage and beverage distribution.

Yes. Material Handling USA designsand installs pallet rack systems across the entire United States. We’re based in Utah and serve clients from coast to coast.

Cost varies by system type, height, capacity, and configuration. Selective rack starts at roughly $150–$300+ per pallet position — and every component is engineered to your exact specifications. High-density systems like mobile rack cost more upfront but deliver lower cost per pallet position. Call (800) 326-4403 for a free quote based on your requirements.

FIFO (first in, first out) means the first pallet loaded is the first one picked — essential for perishables. Pallet flow rack provides automatic FIFO. LIFO (last in, first out) means the most recently loaded pallet is picked first — used in drive-in and push-back systems.

Pallet rack cost per position varies by system type. Selective pallet rack typically costs $40–$80 per pallet position for a standard 3-level setup. High-density systems like push-back and pallet flow cost more per bay but can deliver a lower cost per position because each bay stores more pallets. The best way to compare is to calculate total project cost divided by total pallet positions. Visit our cost and pricing guide for detailed breakdowns, or call (800) 326-4403 for a free project estimate.

Roll-formed pallet rack uses cold-rolled steel that is bent into shape — lighter, less expensive, and suitable for most standard warehouse applications. Structural pallet rack uses hot-rolled steel C-channels and I-beams with bolted connections — heavier, more impact-resistant, and better for abusive environments like cold storage, beverage distribution, and high-traffic forklift areas. Structural rack costs 20–40% more than roll-formed but lasts significantly longer in demanding applications. Material Handling USA supplies both types and will recommend the right one for your environment.

Pallet rack load capacity involves three calculations: (1) Beam capacity — the weight each pair of beams can support, determined by beam size, length, and steel gauge (typically 2,000–12,000 lbs per pair). (2) Frame capacity — total load each upright column can bear, based on column gauge, height, and bracing pattern (typically 15,000–30,000 lbs). (3) Connection capacity — the strength of beam-to-column connectors. All three must be checked, and the lowest value governs. Never load rack beyond its rated capacity — always check the manufacturer capacity label on each frame. Material Handling USA provides engineering calculations and stamped capacity labels with every rack project.

Permit requirements vary by jurisdiction. Many cities and counties require building permits for pallet rack installations over a certain height (commonly 8 or 12 feet), especially in seismic zones. In Utah, most commercial rack installations over 8 feet require a building permit and may need stamped engineering drawings. California, Washington, and other seismically active states have strict permitting requirements. Material Handling USA handles permitting as part of our turnkey installation service — we prepare engineering documents, submit permit applications, and coordinate inspections so you do not have to.

The Rack Manufacturers Institute (RMI) recommends a formal rack inspection program that includes: (1) Daily walk-throughs by forklift operators to spot obvious damage. (2) Monthly documented inspections by a trained employee checking uprights, beams, connections, anchors, and load placement. (3) Annual professional inspections by a qualified rack engineer or inspector who evaluates structural integrity, plumb and level, capacity compliance, and seismic components. Any damaged component should be unloaded and tagged immediately until repaired or replaced. Visit our repair and inspection page for more details.

The most common pallet rack beam sizes are 8-foot (96 inches) and 9-foot (108 inches) in length, designed to span a bay width that accommodates two standard 40×48-inch GMA pallets with clearance for forklift handling. Beam depth (height) typically ranges from 3 inches to 6 inches — deeper beams carry heavier loads. Step beams (with a recessed top flange) are used with wire decking, while box beams provide a flat surface for direct pallet placement. Material Handling USA sizes beams to your specific pallet dimensions and weight requirements — not every warehouse uses standard pallets, and custom beam lengths are available for non-standard applications.